Manufacture

Market
Research

Thermoforming Process

Conceptual
Design

(Vacuum Forming Process)

Design for
Manufacture

Unit
Unit
Manufacturing
Manufacturing
Processes
Processes
Assemblyand
and
Assembly
Joining
Joining
Welding
Bolting
Bonding
Soldering

Factory,
Systems &
Enterprise

Machining
Injection molding
Rapid prototyping
Stamping
Chemical vapor
deposition

Overview

Outline
Polymers

thermoplastic

Overview
Process Steps
Process Equipment
Design for Manufacturing

Applications
packaging, container, housing, etc.

Materials
ABS (~15%), PMMA (~15%), PS (~20%)

Typical Production Flow:

In-line Arrangement

Three-station Thermoforming
Machine
EN
OV )
2

CL

LO

1. roll stock
4. forming station
7. part stacking

2. nip rollers
5. trimming station

3. electric eye
6. scrap wind
5

F
1) RAM
E

/U

NL
OA
D

ST

AT
IO

1. loading and unloading station

2. heating station
3. forming station

Plastic Sheet Making:

Extrusion

Processing Steps

AD

MOLD
3)
AM
P

Sheet
Heat
Form
Cool
Trim

1. feed hopper
3. extruder barrel
5. roller stack
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2. extruder screw
4. die
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Heating Methods:
Radiant Heating

Other Heating Methods

Convection Heating
Contact Heating

1. thermoplastic sheet
2. reflector
3. tubular heater element
4. direct heat
5. reflected heat
6. actual heat distribution on the plastic sheet

Polymers
Amorphous vs Semicrystalline

10

Forming:
Vacuum or Pressure
Positive air pressure
(14.5 to 300 psi)
Faster mold cycle
Lower temperatures
with higher forming
pressure

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++++++++

12

Plug-assist Vacuum Forming

Forming: Match Mold

b
+++++++++

c
B

A: preheated sheet prior to forming

B: sheet stretched with moving plug
C: sheet vacuum formed into female cavity

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a - plug
b - preheated, clamped, sheet
c - female mold with vacuum holes
d - moving plug
e - vacuum

Plug-assist Pressure Forming

Free Blowing

e
a

c
a

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d
g
A

A: preheated sheet prior to forming

B: sheet stretched with mechanical plug advance
C: sheet air-pressure formed into female mold
a - pressure box
c - preheated, clamped sheet
e - moving plug
g - venting air

A: preheated sheet prior to forming

B: free-blown sheet: bubble height determined by photocell monitor.

b - plug
d - female mode with vent holes
f - applied air pressure
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a - preheated clamped sheet

c - proportional photocell monitor
e - hold-down ring

b - pressure box
d - signal to air pressure
f - air pressure
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Vacuum Reverse Draw with

Plug-assist

Billow Vacuum Forming

b

a
c
c

d
B

A: preheated sheet prior to forming

B: sheet prestretched with air pressure
Better thickness uniformity
C: sheet vacuum formed into femaleDeep
cavitydraw
Longer cycle time
a - hold down ring
b - preheated clamped sheet
c - female mold with pressure/vacuum holes,
d - applied pressure
e - vacuum

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Pressure Reverse Draw with

Plug-assist
g
e

h
D

A: preheated sheet prior to forming

B: formation of bubble
C: plug moves into billow, air pressure continues
D: vacuum applied pulling sheet into female mold
a) plug, b) hold-down ring, c) preheated, clamped sheet, d) female mold,
e) plug motion activated when bubble touches it, f) applied air pressure,
g) continuing air pressure as plug advances, h) vacuum
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Forming Mechanism

d
i

f
A

j
D

A: preheated sheet prior to forming

B: sheet prestretched into bubble with air pressure
C: plug moves into sheet while air pressure still on
D: sheet vacuum formed into female mold
a) pressure box, b) plug, c) preheated, clamped, sheet, d) female mold
with air pressure/vacuum holes, e) plug begins to move when billow
touches it, f) applied air pressure, g) air pressure, h) plug moving into
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billow, i) continuing air pressure, j) vacuum

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Forming Considerations:
Part Thickness

Thickness Uniformity

Draw ratio
- depth of part / width of part
Draw ratio should be less
than
- 2:1 for female molds
- 7:1 for male mold
Area ration for blank sheet
size estimation
Draft angle : .5 to 5 degree

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Forming Considerations:
Progressive Draw-Down

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Forming Considerations:
Detail Loss

male form

R
female form

R/8

R/4

R/2

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Forming Considerations:
Vacuum holes

Forming Considerations:
Undercut

ATMOSPHERIC PRESSURE

SELF SEAL

SELF SEAL

BASE

SHEET
UNDERCUT

VACUUM
SOURCE

MOLD

25

26

Cooling
Amorphous vs Semicrystalline

Trim
DIE

V
Rubbery

Melt

Glassy solid

Melt

PUNCH

Tough and
flexible

Brittle

Tg

Tg+60C

(a)

Tg

Tm

(b)
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Punch and die trim tools with different types of punches

1. broad punch
2. shearing punch
3. double-angle shearing punch
4. hollow-ground punch

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Design for Thermoforming

Cost - Thermoforming

Uniform thickness (~10%)

Simpler shapes (avoid under cuts, etc.)
Rounded corners (1t min, 4t ideal)
Draft angle for removal (.5 5 degree)
Depth of draw ratio (< 1:1)
Stretch ratio (< 2:1)
Shrinkage
Design for holes and trim lines

Initial Cost
Equipment cost is low to moderate, but can be high
if automated
Tooling cost is low to moderate depending on the
complexity

Variable Cost
Labor cost is low to moderate
Moderate to low material utilization : unformed part
of the sheet are lost

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30

Quality - Thermoforming

Rate - Thermoforming

Dimensional
Affected by viscoelastic spring back : rate of change
affects spring back
Shrinkage
Surface finish is good and related to the condition of mold
surface

Development time
Die design time : a few days to weeks

Cycle time
Shorter than melting process : 10 to 60 seconds

Mechanical Property

Production rate

Good toughness : orientation related

Usually very fast : but vary with batch size

Defects
Corners tend to become excessively thinner : pre-stretch
in opposite direction and apply pressure
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Flexibility - Thermoforming

Moderate : Die needs to be changed

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